Remove the engine (see Engine Removal in the Engine
Set the engine on a clean surface and hold the engine
steady while parts are being removed.
Cylinder Head (see Cylinder Head Removal in the En-
gine Top End chapter)
Cylinder (see Cylinder Removal in the Engine Top End
Piston (see Piston Removal in the Engine Top End chap-
Clutch Cover (see Clutch Cover Removal in the Clutch
Clutch (see Clutch Removal (KLX110C/D) in the Clutch
Kick Shaft (see Kick Shaft Removal)
Oil Filter and Oil Pump (see Oil Filter Replacement in the
Periodic Maintenance chapter and Oil Pump Removal in
the Engine Lubrication System chapter)
External Shift Mechanism (see External Shift Mecha-
Alternator Rotor (see Alternator Rotor Removal in the
Electrical System chapter)
Starter Motor (see Starter Motor Removal in the Electri-
cal System chapter)
Gear Position Switch (see Gear Position Switch Re-
moval in the Electrical System chapter)
Crankcase Bolts [A]
Screw the crankcase splitting tool [A] into the left side of
the crankcase [B]. Be certain to screw the adapters in all
Special Tool - Crankcase Splitting Tool Assembly: 57001
Tighten the center bolt of the crankcase splitting tool to
split the crankcase.
Once the crankcase is split, remove the crankcase split-
ting tool and separate the crankcase halves.
Remove the crankshaft [A] from the right crankcase half
using a press [B].
Do not remove the ball, needle bearings and the oil
seals unless it is necessary. Removal may damage
Press the bearing out of the crankcase half if the bearing
remains on the crankcase half.